Modular Safety Device for Drive Controllers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing drive controllers require significant time and effort for implementing and extending safety functions, limiting flexibility and user customization, as these functions are predetermined and can only be modified by the manufacturer, necessitating extensive testing and certification.
Innovation Solution
A modular safety device within the drive controller comprising an evaluation unit, control-signal block, drive-signal block, programmable logic unit, and output unit, allowing users to assemble and load logic modules for customizable safety functions, such as stop, speed, and position control, without requiring manufacturer intervention or additional certification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If safety functions are firmly stored and predetermined in the safety device, then reliability is improved, but adaptability deteriorates
Solution Approach 1:
The safety device is divided into a predetermined safety function module (stored in read-only memory) and a programmable logic unit. The predetermined module ensures reliable safety functions, while the programmable logic unit allows customization through user-programmable logic modules, thus resolving the contradiction between reliability and adaptability.
Solution Approach 2:
The safety device combines static predetermined safety functions with dynamic user-programmable logic. The programmable logic unit can be configured differently for various applications while the core safety functions remain predetermined and reliable, enabling the system to adapt to different needs without compromising safety.
2Reliability
If every safety function is fully programmed and tested, then reliability is improved, but time and effort for implementation deteriorates
Solution Approach 1:
The safety functions are predetermined and pre-programmed in the safety device during manufacturing. This preliminary action ensures reliability while allowing users to simply select and activate needed functions through parameter setting rather than full programming, significantly reducing implementation time.
Solution Approach 2:
The safety device is designed as a universal platform with multiple predetermined safety functions that can be activated through parameterization. Users can select from a library of pre-tested safety functions and combine them with custom programmable logic, eliminating the need to fully program and test each function from scratch.
3Speed
If safety functions are executed in the drive controller, then response time is improved, but device complexity increases
Solution Approach 1:
The safety device is integrated into the drive controller as a combined unit. This merging allows safety functions to be executed with the same fast response time as drive control functions while sharing common hardware resources, thus avoiding the need for a separate safety controller and reducing overall system complexity.
4Adaptability or versatility
If the user can extend safety functions, then adaptability is improved, but reliability deteriorates
Solution Approach 1:
The safety device separates predetermined reliable safety functions (stored in read-only memory) from user-programmable logic (in programmable logic unit). Users can extend functionality by programming additional logic modules that work alongside the predetermined functions, maintaining reliability of core safety functions while enabling customization.
Data Source
AI summary
A drive controller comprises an evaluation unit to receive and evaluate a first item of feedback information from a motor connected to the drive controller, a control-signal block connected to secure inputs of the drive controller to receive condition control signals and to provide the condition control signals as input signals, a drive-signal block connected to the evaluation unit to calculate a first speed and/or a first position on the basis of the first item of feedback information on at least a first channel and to provide a first speed signal and/or a first position signal, a programmable logic unit connected to the control-signal block and the drive-signal block to realize the safety functions and the speed signal and/or the position signal to provide switch-off signals, and an output unit connected to the logic unit and to secure outputs of the drive controller to output switch-off signals on safety-switch-off paths.